Alps Electric SPEEDGLIDER Instruction manual

SPEEDGLIDER QUICK-START MANUAL i TM 2012-005 REV00 © 7/24/2012
Air Logic Power Systems, LLC
1745 S. 38th Street, Suite 100 Milwaukee, WI. 53215-1732
Phone: [phone] Fax: [phone]
24 Hour Service Hotline: [phone]
www.alpsleak.com and [e-mail]
ALPS SPEEDGLIDER LINEAR
LEAK TESTER
QUICK-START MANUAL
A quick reference guide for quick setup and startup.

AIR LOGIC POWER SYSTEMS (ALPS) NOTICES
Notices:
Documentation
Air Logic Power Systems, LLC; (ALPS), reserves the right to make changes or improvements to the SpeedGlider™
Linear Leak Tester at any time. These changes may not be immediately reflected in the manual accompanying your
system. If you notice any inaccuracies or oversights in this manual, please contact the ALPS Service Department.
This manual is protected by U.S. federal copyright laws © 2012 Air Logic Power Systems LLC. However, limited
permission is hereby granted to photocopy portions of this manual for training of company personnel only. No part
of this manual may be duplicated or transcribed in any form, for any other purpose, except as stated above, without
expressed written permission from Air Logic Power Systems LLC.
Software
Installation of any new or modification of existing software into the SpeedGlider™ machine not approved by Air
Logic Power Systems LLC may adversely affect the operation or performance of the machine and possibly void the
warranty and or service agreements. Please consult Air Logic Power Systems Service Department prior to installing
or modifying existing software on this machine.
System Modifications
Mechanical or electrical modifications not approved by Air Logic Power Systems LLC to the SpeedGlider™ system
may also void the warranty and/or service agreements. Please contact the Air Logic Power Systems Sales or
Service Department for approval or assistance with any machine modifications.
Trademark and Patent Acknowledgments
All products or product names mentioned in the manual are trademarks of their respective companies. The product
name: SpeedGlider™ is protected under United States patent laws.
Contact Information
Service Department 24 Hour Hotline (US): 1-800-325-8717 (International): 011+800-325-8717
Service Manager, Ext. 199
Sales & Customer Service Support, Ext. 188
Sales Manager, Ext. 184
Air Logic Power Systems; LLC, Headquarters
1745 S.38th Street, Suite 100, Milwaukee, WI. 53215-1732
Phone: [phone] Fax: [phone]
Email: www.alpsleak.com and: [e-mail]
Copyright © 2012 by Air Logic Power Systems, LLC

AIR LOGIC POWER SYSTEMS (ALPS) TABLE of CONTENTS
SPEEDGLIDER QUICK-START MANUAL ii TM 2012-005 REV00 © 7/24/2012
Table of Contents
Section 1: General Information 1
Machine Designation and Serial Number location ................................................................................................2
Hoisting and Transport of this Machine.................................................................................................................3
Installation of the SpeedGlider Machine-refer to the installation manual..............................................................3
Section 2: Safety 4
Safety: Warning Labels and Descriptions .............................................................................................................4
DANGER! ARC, SHOCK, AND FLASH HAZARD:................................................................................................4
WARNING! LOW VOLTAGE CONTROL ENCLOSURE.......................................................................................4
RISK OF HOT SURFACES HAZARD...................................................................................................................4
LOCK OUT / TAG OUT.........................................................................................................................................5
WARNING! WATCH YOUR HANDS AND FINGERS...........................................................................................5
DANGER! DO NOT OPERATE WITHOUT GUARDS IN PLACE.........................................................................5
DANGER: STARTS AUTOMATICALLY................................................................................................................5
Safety: Warning Messages6
Lockout-Tag Out Air supply..................................................................................................................... 7
Safety: Machine is installed and ready for production...........................................................................................8
Section 3: Theory of Operations 10
Basic Theory of ALPS Leak Testing....................................................................................................................10
Theory of Operation Production Modes ..............................................................................................................10
Manual Mode......................................................................................................................................... 10
Auto Modes Introduction........................................................................................................................ 10
SpeedGlider™ Optional Run Modes Table.......................................................................................... 11
Theory of Operation- Photo Eyes........................................................................................................................12
Positions and Functions ........................................................................................................................ 12
Test Probes Carriage/Slide Introduction ............................................................................................... 13
Reject and Reject Verify PE’s Introduction............................................................................................ 14
Section 4: Getting Started15
Main Electrical Power..........................................................................................................................................15
Air Supply ............................................................................................................................................................15
Air Supply description Table................................................................................................................................15
Air Pressure.........................................................................................................................................................15
Access Guards ....................................................................................................................................................16
Container-Present Photo-Eye .............................................................................................................................16
Test Probe Carriage ............................................................................................................................................16
Section 5: RS/RSS Quick Start Operations 17
About The Quick Start Manual ............................................................................................................................17
Section 6: HMI Control Panel Touchscreen Description 18
Section 7: HOME Screen and Main Menu Description 19
Home Screen Button Features and Functions TABLE........................................................................................19
Home Screen / Main Menu Directory Structural Hierarchy: ................................................................................20

AIR LOGIC POWER SYSTEMS (ALPS) TABLE OF CONTENTS
Section 8: Loading a Recipe 21
Recipes Menu Command Overview....................................................................................................................21
Section 9: Production 23
Start Production...................................................................................................................................................23
Monitoring Production..........................................................................................................................................23
Production Quick-View.......................................................................................................................... 23
Accessing Online Information................................................................................................................ 23
Counters................................................................................................................................................ 24
Recent Results ....................................................................................................................................................24
Self-Tests.............................................................................................................................................................25
Recent Rejects ....................................................................................................................................................25
Cycle Timers........................................................................................................................................................26
Bottle Pressure....................................................................................................................................................26
Alarms..................................................................................................................................................................27
Alarms Introduction................................................................................................................................ 27
Speed Variation Alarm........................................................................................................................... 27
Loss of Air Alarm Servo Alarm ....................................................................................................... 27
Test to Long Alarm Total Reject Percent Alarm.............................................................................. 27
Reject Verification Alarm....................................................................................................................... 28
Reject Verification Eye On Alarm.......................................................................................................... 29
H1 to H4 Consecutive Reject Alarms.................................................................................................... 29
H1 to H4 Transducer Alarms................................................................................................................. 30
Reject Percent Alarm H1 to H4............................................................................................................. 30

AIR LOGIC POWER SYSTEMS (ALPS) GENERAL INFORMATION
SPEEDGLIDER QUICK-START MANUAL 1 TM 2012-005 REV00 © 10/16/2012
Section 1: General Information
The SpeedGlider™ Linear machine is designed for medium to high speed production lines requiring leak
inspection. The SpeedGlider™ is built to accommodate the customers’ conveyor equipment. Molded containers
are captured and fed into the test area by a timing screw located adjacent to the line conveyor. The timing screw,
conveyer and test probes are synchronized so that a smooth transition occurs from test cycle to test cycle. After
the test is complete good containers pass on, and defective containers are ejected off of the conveyor line.
A single electrical cabinet is installed on the backside of the machine containing the AC power circuits, variable
frequency drive, DC power supplies, power contactors, and main disconnect.

AIR LOGIC POWER SYSTEMS (ALPS) GENERAL INFORMATION
SPEEDGLIDER QUICK-START MANUAL 2 TM 2012-005 REV00 © 10/16/2012
Machine Designation and Serial Number location
This individual machine is identified with an ID and Serial Number plaque affixed to the inside door surface
of the High Voltage control enclosure as shown below. Along with it are the 24 Hour service hotline phone
number and the UL Panel Rating plate.
High-Voltage Enclosure door: ID plaque, ALPS 24 Hour service phone number, and UL Panel rating label.
TABLE 1 Identification and rating labels.
LABEL
1 ALPS 24 hour service hotline phone number
2 ALPS ID
3 CE Identification and serial number plaque
4 UL Certification Sticker
5 UL Panel and Rating Label
4
5
3
1
2
4
5

AIR LOGIC POWER SYSTEMS (ALPS) GENERAL INFORMATION
SPEEDGLIDER QUICK-START MANUAL 3 TM 2012-005 REV00 © 10/16/2012
Hoisting and Transport of this Machine
The SpeedGlider™ machine must be hoisted in the manner shown by a fork-lift. Forks must be of sufficient
length to support the entire machine. Warning! This machine has a high center of gravity. Do not
transport with forks tilted forward! Forks must remain parallel with the floor. A potential injury hazard
exists as this machine can overturn easily if caution is not observed. Refer to section 2 of the service and
maintenance manual for procedures relating to the transit of this machine to a new location.
Transport: This unit must be fully supported. Forks must extend all the way under the unit. Damage can occur if this is not
observed. Move slowly and station a person at each end during the transport phase to prevent tipping.
Installation of the SpeedGlider Machine-refer to the installation manual
1. Avoid installing this machine near any nearby heat source, such as a blow-molding machine.
Containers should be at their coolest state in order for testing to progress smoothly and without
containers sticking to the probe seal during the testing process.
2. The SpeedGlider™ Linear Leak Tester should be mounted on firm and level floor space. This machine
comes with various height settings. Verify that contact is solid and the machine is level at all four
corners. Adjust all four feet as shown to level the machine. Use a carpenter’s level to accomplish this.
3. Picture below show casters. This is an optional feature that allows for easy and quick movement of the
SpeedGlider™.
Leveling feet with adjustment and wheel locks
Machine Weight:
1000 LBS.: Lift
from control
cabinet side.
Optional
Height
settings
Adjustment
nut. Use a 1
-
1/8” open
-
end
or box
wrench to
adjust. Adjust
lower hex nut
beneath to
tighten foot.

AIR LOGIC POWER SYSTEMS (ALPS) SAFETY
SPEEDGLIDER HMI 4.0.4 LEAK TESTER S/N 10751 4 TM 2012-005 REV00 © 7/24/2012
Section 2: Safety
Safety: Warning Labels and Descriptions
Safety is critical at all times. The ALPS NGR Rotary machine is equipped with a full complement of warning
decals and labels. A standard series of warning and caution labels are in place to inform the operator of certain
hazards relative to the function of this machine. Please observe all of these warnings.
DANGER! ARC, SHOCK, AND FLASH HAZARD:
The potential for serious or fatal injury exists. Label is located on the outer door surface of the High-Voltage
Control enclosure. Do not open to explore or attempt to affect repairs in this area. In case of breakdown, initiate
Lock-Out Tag-Out procedures to secure the machine. Notify authorized personnel.
WARNING! LOW VOLTAGE CONTROL ENCLOSURE
This label is displayed on the outside of the Low Voltage Control enclosure. This area controls power to all
electronic modules on the machine. A potential for serious bodily injury or death exists. In case of breakdown,
initiate Lock-Out Tag-Out procedures to secure the machine. Notify authorized personnel.
RISK OF HOT SURFACES HAZARD
This symbol can be found in areas where a potential burn hazard exists. SpeedGlider servo motors have hot
surfaces. Do not touch motor surfaces while in operation or after being recently shut down.

AIR LOGIC POWER SYSTEMS (ALPS) : SAFETY
SPEEDGLIDER QUICK-START MANUAL 5 TM 2012-005 REV00 © 10/16/2012
LOCK OUT / TAG OUT
This decal appears prominently next to the main power switch on the side of the High Voltage Control cabinet at the
rear of the machine. Lock-out and tag-out procedures are covered in the service and maintenance manual.
WARNING! WATCH YOUR HANDS AND FINGERS.
This warning is seen on the front of the discharge chute. Do not thrust your hand up this chute while the
machine is operating. Contact with moving container material poses a slight to moderate threat of injury
DANGER! DO NOT OPERATE WITHOUT GUARDS IN PLACE
This warning is located on the lower front portion and rear plexiglass guard of the machine. It cautions the
operator not to attempt to operate this machine without a plexiglass guard panel in place. The potential for
severe injury exists while the machine is operating. Please keep hands, long hair, low hanging jewelry, and
loose clothing away from the moving parts.
DANGER: STARTS AUTOMATICALLY
This warning is displayed on all plexiglass doors as a warning that the machine starts and stops automatically
as a function of its normal operating scheme.

AIR LOGIC POWER SYSTEMS (ALPS) : SAFETY
SPEEDGLIDER QUICK-START MANUAL 6 TM 2012-005 REV00 © 10/16/2012
Safety: Warning Messages
Note these Warnings and Cautions:
Cautions: Caution messages can appear before procedures. Messages of this type indicate possible damage to the
machine or loss of data if a step or procedure is not properly observed.
Warnings: Warning messages imply that a potential health hazard exists in the performance of any random
procedure.
THE SPEEDGLIDER LINEAR MACHINE USES 110/220 VOLTS AC POWER WHICH CAN CAUSE
SERIOUS INJURY OR DEATH ON CONTACT. DO NOT DEFEAT THE SAFETY FEATURES OF
THIS EQUIPMENT TO GAIN ACCESS TO INTERNAL VOLTAGES.
VOLTAGE HAZARD!
WARNING!
WARNING! DO NOT WEAR LOOSE CLOTHING, LOW-HANGNING JEWELRY, OR ANYTHING
THAT CAN BECOME ENTANGLED IN THE MOVING CONVEYOR. WOMEN ARE CAUTIONED TO
PIN UP LONG HAIR. THE POTENTIAL FOR SLIGHT TO MODERATE PERSONAL INJURY
EXISTS.
DANGER!
NEVER ATTEMPT TO SERVICE THIS MACHINE WITHOUT FIRST DISCONNECTING
ELECTRICAL AND PNEUMATIC POWER AND PERFORMING LOCK-OUT / TAG-OUT
PROCEDURES. THE POTENTIAL OF SERIOUS PERSONAL OR FATAL BODILY INJURY
EXISTS!
THE DETECTOR CONNECTED TO THE MOLDER ASSEMBLY MAY REACH A TEMPERATURE
SUFFICIENT TO CAUSE SECOND DEGREE BURNS. AVOID CONTACT WITH THESE
COMPONENTS DURING OPERATION OF THE SYSTEM.

AIR LOGIC POWER SYSTEMS (ALPS) : SAFETY
SPEEDGLIDER QUICK-START MANUAL 7 TM 2012-005 REV00 © 10/16/2012
Safety Lockout Tagout:
Lockout-Tag Main Power
Lock main Power in the OFF position when the machine is down for maintenance
.
Lockout-Tag Out Air supply
Lock airflow in the OFF position when the machine is down for maintenance

AIR LOGIC POWER SYSTEMS (ALPS) : SAFETY
SPEEDGLIDER QUICK-START MANUAL 8 TM 2012-005 REV00 © 10/16/2012
Safety: Machine is installed and ready for production
Jokab Emergency Stop devices: The ALPS SpeedGlider™Linear machine is equipped with a pair of door
sensor devices that will stop the machine in the event that one or both enclosure doors are opened during
operation. These are positioned front and center at the base where the doors intersect.
Jokab door-mounted e-stops: Left: Front View. Right: Rear View.
HMI Emergency Stop Palm Button-
The SpeedGlider™is equipped with only one emergency stop (E-Stop) palm-button located on the HMI panel.
The E-Stop button has an LED to indicate the status of the safety system or sensor.
Steady Green indicates the machine is either ready to run or is running production
Steady Red indicates that the circuit is open or interrupted, the E-stop has been pressed or a fault has
occurred.
Red/green indicates that the circuit has been opened by another series-connected sensor (door).

AIR LOGIC POWER SYSTEMS (ALPS) : SAFETY
SPEEDGLIDER QUICK-START MANUAL 9 TM 2012-005 REV00 © 10/16/2012
Safety: Operational Status/Conditional Status
Operational Status: Conditional status of the machine.
TABLE 2: HMI Status LED: Color Code Indicates Running Status.
COLOR
STATUS/CONDITION
Green Normal operating status.
Yellow Machine in bypass Mode or in Pause Condition
Red Machine stopped, door ajar or waiting for operator to press START. The circuit
is open, interrupted, e-stop has been pressed or a fault has occurred.
Clear (No Color) Waiting for run or start condition.

AIR LOGIC POWER SYSTEMS (ALPS) THEORY of OPERATION
SPEEDGLIDER HMI 4.0.4 LEAK TESTER S/N 10587 10 TM 2012-005 REV00 © 7/24/2012
Section 3: Theory of Operations
Basic Theory of ALPS Leak Testing
The product detect photo eye Monitors the line for incoming containers to determine that a container is present to
initiate the test cycle. If containers are present the SpeedGlider test probes will extend and fill valves will execute
simultaneously. At this time pressurization of the container occurs. During this process the container is electronically
monitored to insure the sealed container reaches the specified test settings for the recipe loaded on the SpeedGlider.
If the container fails the leak test it will be rejected and the reason will be reported on the HMI. .
Theory of Operation Production Modes
Containers transitioning from the production line to the SpeedGlider™ for leak testing will be monitored and controlled
by speed mode photo eyes and reject cylinders.
Manual Mode
The machine runs at a pre-set speed, regardless of the backlog or the
presence of containers at the in-feed
Auto Modes Introduction
When containers are present and the SpeedGlider™ is in one of the Auto
modes if the start button is pressed the SpeedGlider™ will run. If there are
no containers on the production line the SpeedGlider™ will go into a
“Paused” condition. In the paused condition the message center will
indicate the SpeedGlider™ is and status light atop
the HMI control box will be
When containers are present the SpeedGlider™ testing cycle will begin
and the status light will turn . If equipped with a fast photo-eye, the
machine will run faster than the normal production rate, allowing the
machine to run high speed lines more efficiently by reducing the backlog
upstream from the leak tester.

AIR LOGIC POWER SYSTEMS (ALPS) : THEORY of OPERATION
SPEEDGLIDER QUICK-START MANUAL 11 TM 2012-005 REV00 © 10/16/2012
SpeedGlider™ Optional Run Modes Table
RUN MODE EYES EYE
MODE FUNCTION
1 Manual
Mode: N/A N/A Product runs at a single (fixed) speed at
all times.
2
Primed;
No-
Backlog
Mode
Uses
Slow
Only
Dark-On
(no
reflectors)
and no
time delay.
Container-present photo-eye: Remains
ON until no containers are present. Speed
is limited to a single setting. The OFF-
delay timer is adjustable and set for a
certain elapsed time (in seconds) after
which timing screw and airflow is shut off.
If containers are detected, the sensor
activates and remains in Slow speed and
restarts the timer.
3
Primed
Backlog
Mode
(Slow
Speed)
Uses
Slow
Only
Dark-On;
Time delay
0.75
seconds
Speed is limited to a single setting. The
timing screw runs only when there is a
minimum backlog of containers present.
The line will start and stop based on
whether the PE is blocked or not blocked.
4
Two
Speed
Mode
(Two
Photo-
Eyes)
Slow
and
medium
Dark-On;
Time delay
0.75
seconds
The unit toggles between (2) speeds
without stopping, based on the level of
backlog as sensed by the (2) upstream
eyes. The purpose of this mode is to
prevent any stop/start motion.
5
Three
Speed
Mode
(Three
Photo-
Eyes)
Slow
medium
and fast
Dark-On;
Time delay
0.75
seconds
The unit switches between low, medium
and high speeds based on the level of
backlog as sensed by (3) upstream eyes
(Slow/Stop, Normal, & Fast Photo-Eyes).

AIR LOGIC POWER SYSTEMS (ALPS) : THEORY of OPERATION
SPEEDGLIDER QUICK-START MANUAL 12 TM 2012-005 REV00 © 10/16/2012
Theory of Operation- Photo Eyes
Positions and Functions
:
1. Container Present Photo-Eye: Monitors the line for incoming containers to determine that a container is
present to initiate the test cycle.
2. Slow/Stop Photo-Eye: When this sensor is not blocked and there are no more containers to be tested the
machine will go idle.
3. Medium Photo-Eye: Controls machine speed. Reduces the machine speed from normal to slow speed when
the volume of containers has thinned-out or cleared the sensor field.
4. Fast Speed Photo-Eye: Accelerates the machine into fast speed when the sensor field is blocked.
5. Downstream Jam Photo-Eye: Temporarily idles (pauses) the machine when the sensor field is broken. It
automatically restarts the machine when the sensor field is clear.
6. Reject Verification/: Verifies that rejected containers have left production line. If the sensor fails to detect the
container, or if the sensor field has not been broken after a reject occurs, the machine and conveyor will shut
down and an alarm condition called a Reject Verification Fault is generated.
Note: Reject Verification Failure: Any defective containers must be removed from the line manually
Auto Mode Photo eye condition & response Table
CONDITION MACHINE RESPONSE
SLOW EYE BLOCKED* RUN SLOW SPEED
SLOW EYE CLEAR STOP or PAUSE
MEDIUM EYE BLOCKED RUN NORMAL SPEED
MEDIUM EYE CLEAR RUN SLOW SPEED
FAST EYE BLOCKED RUN FAST SPEED
FAST EYE CLEAR RUN NORMAL SPEED
*If the machine is waiting for containers, the machine response will not change until both the slow
and medium eyes are blocked

AIR LOGIC POWER SYSTEMS (ALPS) : THEORY of OPERATION
SPEEDGLIDER QUICK-START MANUAL 13 TM 2012-005 REV00 © 10/16/2012
Test Probes Carriage/Slide Introduction
Probe Carriage (slide)
The probe(s) detect leaks by monitoring air pressure inside the containers during tests. The probe(s) can detect
defective containers by sensing either sudden or slow, gradual changes in pressure.
The test settings (parameters) can be fine-tuned for specific types of containers that have different volumes,
shapes, and wall material. Changes in pressure will determine which containers are accepted or rejected. Test data
on rejects is recorded in total numbers as a percentage of the total tests. The data can be used to adjust the
production process to reduce the number of rejects. When test settings (parameters) for a particular container are
set, they can be stored as a recipe and recalled later.
Important: Please do not attempt to service the probe carriage or attempt any modifications. Contact the
24 –hour ALPS SERVICE HOTLINE for help with service questions.

AIR LOGIC POWER SYSTEMS (ALPS) : THEORY of OPERATION
SPEEDGLIDER QUICK-START MANUAL 14 TM 2012-005 REV00 © 10/16/2012
Reject and Reject Verify PE’s Introduction
Air Reject Nozzle
When a container is deemed defective the Reject Nozzle will eject the defective container from the line.
Reject Verify Photo-Eye (optional)
When the container is defective, a reject nozzle (shot of air) kicks it off the line. The container is supposed to fall
down through the reject chute and into the reject bin. The reject verify PE detects the container being ejected. If the
rejected container fails to break the reject verify photo-eye beam, then a reject verification fault occurs, and the
machine will execute an emergency stop. If the container became lodged on the conveyor or the reject air blast was
defective the container can be retrieved and disposed of it in the proper manner. The Reject and the Reject
Verification can be enabled or disabled in the Settings screen for Reject Verfication.
Note: If a Reject Verification Failure occurs, any defective containers must be removed from
the line manually!
Reject Verification Photo-Eye
Reject
Verification
Sensor
Reject
Verification
Reflector
Air Reject Valve

AIR LOGIC POWER SYSTEMS (ALPS) GETTING STARTED
SPEEDGLIDER QUICK-START MANUAL 15 TM 2012-005 REV00 © 7/24/2012
Section 4: Getting Started
Ensure the Following Tasks are Complete:
Main Electrical Power Switch on
The main power switch is located at the front of the high-voltage enclosure.
Air Supply
Hook up air supply and make sure Air on/off switch is in the on position
The Air Sensor and Regulator unit is on backside of machine.
Air Supply description Table
Air Pressure Verify
The gauge should be set between 85 and 100 psi.
Turn the adjustment ring to vary the outgoing air
pressure
ITEM
FEATURE
DESCRIPTION
1 Primary Particulate Filter. Cleans and regulates incoming, compressed air
supply. Indicates a lockout valve, primary
particulate filter, coalescing filter, reject supply
regulator and machine supply regulator.
2 Coalescing Air Filter ---
3 Incoming Air Sensor & Reject
Air Pressure Sensor monitors incoming air
pressure. The
machine will automatically stop if the sensor
detects insufficient air pressure.
ON
(I)
OFF
(0)

AIR LOGIC POWER SYSTEMS (ALPS) GETTING STARTED
SPEEDGLIDER QUICK-START MANUAL 16 TM 2012-005 REV00 © 7/24/2012
Access Guards
Make sure they are closed.
Container-Present Photo-Eye
Adjustment
From job to job, the container Present photo-eye may require adjusting to accommodate small or large
containers.
To adjust the photo eye insert a sample container into the timing screw area where the photo eye is, and adjust
vertically and horizontally with the hand clamp device as shown. The optimum distance from the container is 1/8
of an inch.
Test Probe Carriage
Ensure the probes are set to the proper Height of ¼ inch clearance